< Previous30 Food & Drink International www.fdiforum.net DEPOSITORS AND FILLING All filler Depositors and filling machines are essential in any food industry environment requiring an even distribution of ingredients between separate food items. We take a closer look at these vital machines. T hough depositors and filling machines carry out slightly different functions, they are each used for dosing or dispensing an exact amount of a mixture onto a conveyer or surface, or into a container. For instance, while depositors can portion out soft doughs, fillings or batter – sometimes using a guillotine to slice harder dough – filling machines dispense set levels of a liquid or semi-liquid product into a variety of vessels, such as bottles or pouches. Most depositors are simple machines by design, thanks to their individual function. But it is still possible to customise them to suit any purpose or production line by size and level of output. A micro depositor is the smallest available, bench mounted and easily portable, and able to have its place in any size of factory. They can also be fully or semi-automatic, depending on whether they’ll be used with or without a conveyor, but will only handle deposits in small volumes. Levelling up a step from there, a table top depositor will have many of the same design features, but becomes more useful for successive runs of short batches. As these machines get to the upper levels of size and cost, however, they grow to be of use only to medium or large scale factory operations. With the right amount of space available on the production floor, further conveyors, rotary pot machines or FFS (form, fill and seal) elements can be added on, sometimes for use in tandem with a larger self-contained hopper, as desired for maximum productivity. For further customisation when depositing requirements are varied, more bespoke designs can be brought in. A pillar lift depositor employs a telescopic lift for adjusting the nozzle height when filling multiple sizes of All filler 30-33.qxp_Layout 1 24/10/2022 11:08 Page 1Food & Drink International 31 www.fdiforum.net container, ensuring accuracy and hygiene with every batch run. Hopper agitation functions can be combined in a depositor able to hold solid particles in suspension, when handling ingredients such as soups, stews or pie fillings. Every specificity of function can be accounted for, up to and including needs like sandwich filling; depositors for this particular function can feature multiple head depositors for indexing different fillings, and rise and fall nozzles for clean cut-off when product flow is stopped between deposits. In comparison to depositors, filling machines have a wider variety of applications. Just a few container types that need filling machines for accuracy and quality assurance include cans, cartons, bags and jars, as well as the aforementioned bottles and pouches. The dosing of food products can be achieved by several means, using a variety of machines with their own method and function. They can be floor standing or portable and, like depositors, as compact or large as needed for any production line. Single nozzle machines are ideal for a small enterprise approach, being © stock.adobe.com/ Syda Productions 32 Á 30-33.qxp_Layout 1 24/10/2022 11:08 Page 232 Food & Drink International www.fdiforum.net DEPOSITORS AND FILLING can dispense a range of ingredients – including fine powders with the correct auger system – into a multitude of different container types, and can come available with electric and mechanical interfaces. More functions may also be added on to reduce steps, making the whole processing run quicker and easier to manage. A pouch opening and filling machine can be made to suit most pouch types, filling them effectively and safely, whether standard, screw top, zipped or otherwise. They can be trusted to handle hot or cold ingredients of any consistency, from liquids to suspended solids, or even pastes, creams, powders or granules in some cases. These ingredients can be dispensed directly from a hopper or via connection with a cooking kettle outlet. The only concern for an operator is placing the required pouch, which may be of any size or material, flat onto a forming cone, ready to be opened with clean air. The topic of form fill seal machines was glossed over earlier as an add-on alongside depositors, but these are more than just an optional extra in many fast-paced factories, capable of forming a package into a shape suitable for filling, then dosing out ingredients and sealing as an all-in-one unit. Available in vertical (VFFS) and horizontal (HFFS) types, the latter is used for items that suits being produced and stored horizontally, such as sachets, blister packs and flow-wrapped food items. FFS machines work by dispensing packaging from a roll, before being shaped and closed on all sides except the designated opening. Each pack is then filled, before the opening is securely sealed for easy transportation and distribution, food safety, shelf life and freshness. These systems can be complex and sophisticated, but user- friendly computer interfaces make control settings as simple as possible, and keep production going at a fast rate. Speed and flow are what FFS machines are designed to facilitate in a production process, being an important part of high-demand sectors like snack and single-serve package production, where rapid changeover between items is crucial. This type of machine is also versatile for factories producing a range of food types, enabling the quickest possible shift between packaging formats. It could be said that flow is the value that all depositors and filling machines have in common; for every factory floor there is an ideal combination of machines, which will safely shepherd products from cooking and mixing, right through to the packaging carrying them to stores, stockists and homes. affordable and more than efficient enough for a limited or specialty operation, or for those just starting out in the food industry. Being small and simple in function, they are versatile and therefore suitable for many different ingredients and food types, including sauces, salad dressings, cake mix, or even more viscous matter like jams and spreads. Opting for a multi-nozzle machine simply ups the output achievable with each batch, as more containers can be placed under the multiple filling heads to provide more filled containers with every action of the machine. These can handle all the most common products that need dispensing into a container, including juices, milks, yoghurt, or health beverages such as probiotic and sports drinks. Many such systems are expressly designed to accommodate containers that need to be handled with care, like glass jars and squeezy plastic bottles, with options such as scroll feed conveyors, and design versatility for many different container types and sizes. Certain machines have the added capacity to automatically cap and label products, for even quicker batch completion. Depending on your factory, output and efficiency can be optimised by arranging filling heads and the best way for your line, whether on a rotary filler, or in a row for linear filling. Either option © stock.adobe.com/ 9dreamstudio 30-33.qxp_Layout 1 24/10/2022 11:09 Page 3 LOGKLL DH\UHYRHYDKORFH 26*1,3083 2(02+(+7 . 12,78/2 2&6,9) 2 IRVUD VQRLWDFLOSSDODLUWVXGQL HJVDOOHZVDVWHNUDP RFGQDODFLWXHFDPUDKS WQLVWFXGRUSVXRFVLYIR JQLOGQDKQLHFQHLUHS[H ODUHQ VFLWHPVR GRRIHKW VHS\WOODJ ZVWFXGRUSIRHOSPDV$ 6ᅚ DUDFVD0ᅚ \OOH-PXHORUWH3ᅚ \HQR+ᅚ ƁSPXS\GDHUODHZ HHUX3RWDPR7ᅚ OH*JQLKWHH7ᅚ EXUF6HFD)ᅚ [D:ᅚ PD-ᅚ WOD0ᅚ HWVDSKWRR7ᅚ HWVD3WLXU)ᅚ &\UDQLUHWH9ᅚ KG$ODFLGH0ᅚ NXRFORFHNZZZ: NXRFORFHN#VHODV( 7 [D:QLIIDUD3ᅚ HWVD3WDH0ᅚ WQHPWQL2H\(ᅚ VHFQHVV(ᅚ VVRO*SL/ᅚ QLORQD/ᅚ VHFXD6ᅚ VPDHU& VHYLVHK NXRFORFHNZZZ: See us at See us at Stand No. 4E 02 30-33.qxp_Layout 1 24/10/2022 11:09 Page 434 Food & Drink International www.fdiforum.net SOUPS AND SAUCES New takes on an old classic Soups have been a staple of the human diet for thousands of years, and sauces as well, and yet the changing demands of consumers means the industry doesn’t stay still for long. D emand for soups tends skyrocket during the winter months, as an easy to prepare meal which is perfect for chilly evenings. As with the rest of the food industry, the demand for vegan and vegetarian products is on the rise. As perfect ways to integrate extra flavour and nutrition, it’s easy to see why sauces are in such high demand. The emphasis on reduced sugar, salt, and fat in sauces has led to recent innovation in ingredient formulations. Consumers are looking for soups and sauces that are nutritional as well as flavoursome. The first trend is switching imported ingredients for locally sourced ones. The conflict in Ukraine and the continued impact of Covid-19 has caused major disruption to the supply chain. Ready to eat soup manufacturers that already source locally have seen stability (and growth) where those who outsource raw materials are finding it difficult to cater to the rising demand for canned goods. For example, the Campbell Soup Company (based in the US) sources roughly 90% of its’ raw materials within the US. Having established local suppliers means that Campbell’s has been able to meet pandemic related demand for canned soup, and even grow its market share as its competitors face a severe lack of supply. With this in mind, here’s why you should look at local sourcing as an opportunity rather than a necessary pivot. For one, locally grown food simply tastes better. The material has a higher rate of respiration once separated from its source, which results in nutrient degradation, loss of moisture and even potential growth of microorganisms, spoiling the taste and texture. Locally produced food has been allowed to ripen fully, which means the material has the richest colour and flavour and retains the highest possible nutritional value. When considering the demand for healthier ready to eat options, top quality raw materials is the easiest way to ensure high nutritional value of the end product. Choosing local ingredients helps to support local farms, which ensure the longevity of the local farming community. This is vital for long term food security, especially with the rising costs of energy. Helping the local community will establish good will with both consumer and supplier, and will form a brand identity. It is also more environmentally friendly, as sourcing food locally removes the need for fuel intensive transportation. The average raw ingredient has travelled 1,500 miles by the time it is consumed. Given the calming, nutritious and hearty image that soup brings to mind, basing a brand around caring values will cement a product as the go-to when people need comfort food. As alluded to above, the vegetarian and vegan market is continuing to grow. Vegetarian ready to eat soup already accounts for nearly a third of the 36 Á New takes on an old classic 34-37.qxp_Layout 1 24/10/2022 11:12 Page 1Food & Drink International 35 www.fdiforum.net SOUPS AND SAUCES © stock.adobe.com/ Andrey 34-37.qxp_Layout 1 24/10/2022 11:12 Page 236 Food & Drink International www.fdiforum.net Manufacturing tomato ketchups with high shear mixers In the video ‘How to manufacture tomato ketchups’, the different methods of production are explained, showing how a high shear mixer can improve the process. The video demonstrates how a Silverson mixer can rapidly dilute concentrated tomato paste along with other ingredients. In subsequent processes the mixture can either be passed through a high pressure homogeniser to activate the thickening effect of pectin in the tomato paste, or gums and thickeners are incorporated to obtain the required viscosity. Where a homogeniser is used, the ketchup can be passed through a Silverson mixer afterwards to give the product a smooth consistency and glossy appearance. If thickening agents are used, a Silverson high shear mixer will rapidly produce a homogenous solution of powdered ingredients and will maximize yield of thickening effect. To see the video or read the full application report visit www.silverson.co.uk overall market, and demand is expected to have grown around 5% by the end of the year. This is being seen globally, as the South Asian market is expected to see a revenue growth of 2.5 times. Research shows this is due to the growing awareness of the carbon footprint of animal-based products, as well as the health benefits of a vegetarian diet. Luckily, there are some trending vegetarian and health focussed soup recipes hitting the market. Firstly, the direction is for lighter soups to be fleshed out with rice noodles. The rise in European appreciation for East Asian cuisine can be attributed to this. These lighter soups are often comprised of green vegetables (such as pea, courgette and broccoli) with a coconut base for added richness and sweetness. Another trending ingredient is cauliflower, which is proving a popular rice alternative. When blended, it makes a smooth and nutritious base for soup, and more dynamic flavourings can be added on top (such as tahini). Adding spice creates an aromatic aura around the soup, which makes it nourishing for the soul as well as the body. © stock.adobe.com/ Maresol 34-37.qxp_Layout 1 24/10/2022 11:12 Page 3Food & Drink International 37 www.fdiforum.net SOUPS AND SAUCES Apply Now… 0044 (0) 20 8446 7127 info@halalfoodauthority.com www.halalfoodauthority.com London - Ireland - Belgium EXPLORE OPPORTUNITIES Get Halal Certified Halal Food Authority is an industry leading Halal Food Certification Company. We specialise in Halal Certification of Food and Non-Food items including cosmetics, logistics, chemicals, additives & aromas, cleaning substances, packaging, pharmaceutical, ingredients and much more. Our certification is globally recognised including GCC countries and other developing markets such as Saudi Arabia, UAE, Qatar, Oman, Bahrain, Kuwait, Jordan, Egypt, Malaysia, Indonesia, Singapore, Turkiye, Pakistan and rest of the world. Talking of spices, the demand for adding a kick to meals is also being seen across the sauces market. Latin American flavours and ingredients are particularly popular, such as jalapeno and chipotle (which is smoked jalapeno), hot mustard and smoked paprika. Similarly to soups, inspiration is also being taken from Asian cuisine in the form of gochujang (a red chilli pepper paste), yuzu, and harissa. These are being seen particularly in BBQ and aioli (a garlic and olive oil mixture) as an accompaniment to vegetarian dishes comprised of blander base vegetables, such as poke bowls. Healthy herbaceous plants can also provide heat, such as ginger. With rainbow salads gaining popularity for their flavour and health benefits, tropical flavours like banana, guava and mango make perfect dressings. Spices are also known for their immunity boosting properties, and the heat is even known to burn calories. Switching chemical additives for natural spice adds flavour without the extra calorie count. Emphasising the potential health benefits of ingredients will entice health-conscious consumers who seek functional ingredients within their meals. Sauces that play a role within a holistic diet are gaining traction. A prime example of this is kimchi, which is fermented cabbage. The fermentation adds an umami flavour, and radish is often added to give it heat. Kimchi has exploded as an additive on the sauce market and has inspired ranges of fermented hot sauces. The research shows that consumers are always on the hunt to combine the deliciousness and convenience of ready to eat soups, whilst getting the nutritional benefits of homemade meals. Embracing this, and the continued trend for reduced animal produce, will ensure your continued share of the market. This is also seen within the sauce market – advertising low sodium and fat offerings has been seen to increase sauce sales. However, consumers are on the hunt for sauces which pack a punch. To gain an edge, manufacturers should be seeking to combine the two by utilising healthy ingredients known for their intense flavour, and marketing these to hot sauce devotees. © stock.adobe.com/ anaumenko 34-37.qxp_Layout 1 24/10/2022 11:12 Page 438 Food & Drink International www.fdiforum.net FACILITIES MANAGEMENT F acilities management can be most effectively described as “ensuring the facility operates,” but that term misses out on some of the key nuances of proper management. While it’s important that any facility – be it an office, distribution centre or factory – runs to its minimum requirements, facilities management is more than just making sure the doors open and the equipment works. It is ensuring that the space and the facilities available work to the highest standards available, reducing the stress and distractions that those who work there need to deal with, and thus in the long-term making a business more streamlined and more efficient. Gone are the days where managers might seek to drive their staff into exhaustion in efforts to increase productivity – as we now know that a workforce which is able to maintain an efficient pace continuously, is more valuable than one that is burned out too soon. Recent times have made this especially clear as, with COVID, the lockdown, the soaring energy costs and now the Great Resignation and difficulties in recruitment, getting the most out of your employees is slowly giving way to making sure your employees stay with you for the long run. With so much uncertainty in the air at the moment, especially for those doing work in the UK, there is a push towards offsetting costs through overheads, rather than hoping for that lucky break on a new contract that may or may not materialise. For many in the food and drink industry, when facilities management is mentioned, this refers to some form of manufacturing plant or processing line. Often with tens of Getting the most out of a facility Facilities management has changed over the years as ever more challenging conditions force companies to try and squeeze more out of less, and make the most of what they have rather than invest in more. 38-41.qxp_Layout 1 24/10/2022 11:15 Page 1Food & Drink International 39 www.fdiforum.net FACILITIES MANAGEMENT thousands of units travelling through the system on a daily basis. The smallest hiccups with efficiency on such a line can have drastic effects through the entire system and considering that large retailers are some of the least forgiving in terms of deadlines, and that there are many competitors in this industry, then it becomes obvious that companies cannot afford to take any risks in this regard. Automating the system wherever possible is the preferred method of increasing efficiency, as this takes out the ever-unreliable human element which could slow things down. On a managerial level, software can be used to ease the burden on an Operations Manager, by organising and arranging shift hours based on delivery times of raw materials to the processing plant. This removes another task for the manager to try and deal with, while also © stock.adobe.com/nikomsolftwaer 40 Á 38-41.qxp_Layout 1 24/10/2022 11:15 Page 2Next >